SERIES

TIG200P AC/DC
STICK • TIG
 CONTENT
1. SAFETY • 4
1.1. SIGNAL EXPLANATION • 4
1.2. ARC WELDING DAMAGE • 4
1.3. THE KNOWLEDGE OF ELECTRIC AND MAGNETIC FIELDS • 7

2. SUMMARY • 8
2.1. BRIEF INTRODUCTION • 8
2.2. MODULE EXPLANATION • 9
2.3. WORKING PRINCIPLE • 10
2.4. VOLT-AMPERE CHARACTERISTIC • 10

3. INSTALLATION & ADJUSTMENT • 11

3.1. PARAMETERS • 11
3.2. DUTY CYCLE & OVER-HEAT • 12
3.3. MOVEMENT & PLACEMENT • 12
3.4. POWER SUPPLY INPUT CONNECTION • 13
3.5. POLARITY CONNECTIOn (MMA) • 13
3.6. ASSEMBLING THE EQUIPMENT (TIG) • 14

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4. OPERATION • 15
4.1. LAYOUT FOR THE PANEL • 15
4.2. CONTROL PANEL • 16
4.2.1. PEDAL SWITCH CONTROL • 19
4.2.2. GUN SWITCH CONTROL CURRENT • 29

4.3. ARGON ARC WELDING OPERATION • 20

4.3.1. TIG WELDING (4T OPERATIOn) • 20
4.3.2. TIG WELDING (2T OPERATION) • 21

4.4. WELDING PARAMETERS • 22

4.4.1. JOINT FORMS IN TIG/MMA • 22
4.4.2. THE EXPLANATION OF WELDING QUALITY • 22
4.4.3. TIG PARAMETERS MATCHING • 23

4.5. OPERATION ENVIRONMENT • 26

4.6. OPERATION NOTICES • 26

5. MAINTENANCE & TROUBLESHOOTING • 27

5.1. MAINTENANCE • 27
5.2. TROUBLESHOOTING • 28
5.3. ELECTRICAL PRINCIPLE DRAWING • 31

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 1. Safety
• 1.1. Signal Explanation

 The above signals mean warning! Notice! Running parts and getting an electric shock or thermal
parts will take damage for your body or others. The corresponding notices are as follows. It is
quite a safe operation after taking several necessary protection measures.

• 1.2. Arc Welding Damage

 The following signals and word explanations are to some damages for your body or others
happening on the welding operation. While seeing these, please remind of yourself or others to
be dangerous.
 Only ones who are trained professionally can install, debug, operate, maintain and repair the
equipment.
 During the operation, non-concerned people should be lift, especially for children.
 After shut off the machine power, please maintain and examine the equipment according to §5
because of the DC voltage existing in the electrolytic capacitors.

ELECTRIC SHOCK CAN KILL.

 Never touch electrical parts.
 Wear dry, hole-free gloves and clothes to insulate yourself.
 Insulate yourself from work and ground using dry insulation. Make certain the insulation is large
enough to cover your full area of physical contact with work and ground.
 Take carefully when using the equipment in small place, falling-off and wet circumstance.
 Never close the machine power before installation and adjustment.
 Ensure to install the equipment correctly and ground the work or metal to be welded to a good
electrical (earth) ground according to the operation manual.
The electrode and work (or ground) circuits are electrically “hot” when the welder is on. Do not
touch these “hot” parts with your bare skin or wet clothing. Wear dry, hole-free gloves to insulate
hands.
 In semiautomatic or automatic wire welding, the electrode, electrode reel, welding head, nozzle
or semiautomatic welding gun are also electrically “hot”.

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 Always be sure the work cable makes a good electrical connection with the metal being welded.
The connection should be as close as possible to the area being welded.
Maintain the electrode holder, work clamp, welding cable and welding machine in good, safe
operating condition. Replace damaged insulation.
 Never dip the electrode in water for cooling.
 Never simultaneously touch electrically “hot” parts of electrode holders connected to two
welders because voltage between the two can be the total of the open circuit voltage of both
welders.
 When working above floor level, use a safety belt to protect yourself from a fall should you get a
shock.

FUMES AND GASES CAN BE DANGEROUS.

 Welding may produce fumes and gases hazardous to health. Avoid breathing these fumes and
gases. When welding, keep your head out of the fume. Use enough ventilation and/or exhaust at
the arc to keep fumes and gases away from the breathing zone. When welding with electrodes
which require special ventilation such as stainless or hard facing or on lead or cadmium plated
steel and other metals or coatings which produce highly toxic fumes, keep exposure as low as
possible and below Threshold Limit Values using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a respirator may be required. Additional
precautions are also required when welding on galvanized steel.
 Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing, cleaning
or spraying operations. The heat and rays of the arc can react with solvent vapors to form
phosgene, a highly toxic gas, and other irritating products.
 Shielding gases used for arc welding can displace air and cause injury or death. Always use
enough ventilation, especially in confined areas, to insure breathing air is safe.
 Read and understand the manufacturer’s instructions for this equipment and the consumables
to be used, including the material safety data sheet and follow your employer’s safety practices.

ARC RAYS CAN BURN.

 Use a shield with the proper filter and cover plates to protect your eyes from sparks and the
rays of the arc when welding or observing open arc welding.
 Use suitable clothing made from durable flame-resistant material to protect your skin and that
of your helpers from the arc rays.
 Protect other nearby personnel with suitable, non-flammable screening and /or warn them not
to watch the arc nor expose themselves to the arc rays or to hot spatter or metal.

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SELF-PROTECTION
 Keep all equipment safety guards, covers and devices in position and in good repair. Keep
hands, hair, clothing and tools away from V-belts, gears, fans and all other moving parts when
starting, operating or repairing equipment.
 Do not put your hands near the engine fan. Do not attempt to override the governor or idler by
pushing on the throttle control rods while the engine is running.

DO NOT adds the fuel near an open flame welding arc or when the engine is running. Stop the
engine and allow it to cool before refueling to prevent spilled fuel from vaporizing on contact with
hot engine parts and igniting. Do not spill fuel when filling tank. If fuel is spilled, wipe it up and do
not start engine until fumes have been eliminated.

WELDING SPARKS can cause fire or explosion.

 Remove fire hazards from the welding area. If this is not possible, cover them to prevent the
welding sparks from starting a fire. Remember that welding sparks and hot materials from
welding can easily go through small cracks and openings to adjacent areas. Avoid welding near
hydraulic lines. Have a fire extinguisher readily available.
 Where compressed gases are to be used at the job site, special precautions should be used to
prevent hazardous situation.
 When not welding, make certain no part of the electrode circuit is touching the work or ground.
Accidental contact can cause overheating and create a fire hazard.
 Do not heat, cut or weld tanks, drums or containers until the proper steps have been taken to
insure that such procedures will not cause flammable or toxic vapors from substances inside. They
can cause an explosion even though they have been “cleaned”.
 Vent hollow castings or containers before heating, cutting or welding. They may explode.
 Sparks and spatter are thrown from the welding arc. Wear oil free protective garments such as
leather gloves, heavy shirt, cuff less trousers, high shoes and a cap over your hair. Wear ear plugs
when welding out of position or in confined places. Always wear safety glasses with side shields
when in a welding area.
 Connect the work cable to the work as close to the welding area as practical. Work cables
connected to the building framework or other locations away from the welding area increase the

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possibility of the welding current passing through lifting chains, crane cables or other alternate
circuits. This can create fire hazards or overheat lifting chains or cables until they fail.

Rotating parts may be dangerous.

 Use only compressed gas cylinders containing the correct shielding gas for the process used and
properly operating regulators designed for the gas and pressure used. All hoses, fittings, etc.
should be suitable for the application and maintained in good condition.
 Always keep cylinders in an upright position securely chained to an undercarriage or fixed
support.
 Cylinders should be located:
Away from areas where they may be struck or subjected to physical damage.
A safe distance from arc welding or cutting operations and any other source of heat, sparks, or
flame.
 Never allow the electrode, electrode holder or any other electrically “hot” parts to touch a
cylinder.
 Keep your head and face away from the cylinder valve outlet when opening the cylinder valve.
 Valve protection caps should always be in place and hand tight except when the cylinder is in
use or connected for use.

• 1.3. The knowledge of Electric and Magnetic Fields

Electric current flowing through any conductor causes localized Electric and Magnetic Fields
(EMF). The discuss on the effect of EMF is ongoing all the world. Up to now, no material evidences
show that EMF may have effects on health. However, the research on damage of EMF is still
ongoing. Before any conclusion, we should minimize exposure to EMF as few as possible.
In order to minimize EMF, we should use the following procedures:
 Route the electrode and work cables together – Secure them with tape when possible.
 All cables should be put away and far from the operator.
 Never coil the power cable around your body.
 Make sure welding machine and power cable to be far away from the operator as far as possible
according to the actual circumstance.
 Connect the work cable to the workpiece as close as possible to the area being welded.
 The people with heart-pacemaker should be away from the welding area.

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 2. SUMMARY
• 2.1. Brief Introduction
TIG200E AC/DC welding machine adopts the latest pulse width modulation (PWM) technology and
insulated gate bipolar transistor (IGBT) power module, which can change work frequency to
medium frequency so as to replace the traditional hulking work frequency transformer with the
cabinet medium frequency transformer. Thus, it is characterized with portable, small size, light
weight, low consumption and etc.

The parameters of TIG200E AC/DC on the front panel all can be adjusted continuously and
steplessly, such as start current, crater arc current, welding current, base current, duty ratio,
upslope time, downslope time, pre-gas, post-gas, pulse frequency, AC frequency, balance, hot
start, arc force and arc length etc. When welding, it takes high frequency and high voltage for arc
igniting to ensure the success ratio of igniting arc.

TIG200E AC/DC Characteristics:

- MCU control system, responds immediately to any changes.
- High frequency and high voltage for arc igniting to ensure the success ratio of igniting arc,
the reverse polarity ignition ensures good ignition behavior in TIG-AC welding.
- Avoid AC arc-break with special means, even if arc-break occurs the HF will keep the arc
stable.
- Pedal control the welding current.
- TIG/DC operation,If the tungesten electrode touches the workpiece when welding, the
current will drop to short-circuit current to protect tungsten.
- Intelligent protection: over-voltage, over-current, over-heat, when the problems listed
before occurred, the alarm lamp on the front panel will be on and the output current will be
cut off. It can self-protect and prolong the using life.
- Double purposes: AC inverter TIG/MMA and DC inverter TIG/MMA, Excellent performance
on Al-alloy, carbon Steel, stainless Steel, titanium

According to choosing the front panel functions, the following six welding ways can be realized.
 DC MMA
 DC TIG
 DC Pulse TIG
 AC MMA
 AC TIG
 AC Pulse TIG

1. For DC MMA, polarity connection can be chosen according to different electrodes，please

refer to §3.5;

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2. For AC MMA, magnetic flow caused by invariable DC polarity can be avoided;
3. For DC TIG, DCEP is used normally (workpiece connected to positive polarity, while torch
connected to negative polarity). This connection has many characters, such as stable welding
arc, low tungsten pole loss, more welding current, narrow and deep weld;
4. For AC TIG (rectangle wave), arc is more stable than Sine AC TIG. At the same time, you can
not only obtain the max penetration and the min tungsten pole loss, but also obtain better
clearance effect.
5. DC Pulsed TIG has the following characters: 1) Pulse heating. Metal in Molten pool has short
time on high temperature status and freezes quickly, which can reduce the possibility to
produce hot crack of the materials with thermal sensitivity. 2) The workpiece gets little heat.
Arc energy is focused. Be suitable for thin sheet and super thin sheet welding. 3) Exactly
control heat input and the size of the molten pool. The depth of penetration is even. Be
suitable for welding by one side and forming by two sides and all position welding for pipe. 4)
High frequency arc can make metal for microlite fabric, eliminate blowhole and improve the
mechanical performance of the joint. 5) High frequency arc is suitable for high welding speed
to improve the productivity.

TIG200E AC/DC -series welding machine is suitable for all positions welding for various plates
made of stainless steel, carbon steel, alloyed steel, titanium, aluminium, magnesium, cuprum, etc,
which is also applied to pipe installment, mould mend, petrochemical, architecture decoration,
car repair, bicycle, handicraft and common manufacture.
MMA — Manual Metal Arc welding;
PWM — Pulse-Width Modulation;
IGBT — Insulation Gate Bipolar Transistor
TIG — Tungsten Insert Gas welding

• 2.2. Module Explanation

The module explanation of arc welding machine must accord with the correlative prescripts of
National Standard GB10249. It is explained as the following (take TIG 200 AC/DC as an example).

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• 2.3. Working Principle
The working principle of TIG200E AC/DC welding machines is shown as the following figure.
Single-phase 220V work frequency AC is rectified into DC (about 312V), then is converted to
medium frequency AC (about 40KHz) by inverter device (IGBT module), after reducing voltage by
medium transformer (the main transformer) and rectifying by medium frequency rectifier (fast
recovery diodes), then is outputted DC or AC by selecting IGBT module. The circuit adopts current
feedback control technology to insure current output stably. Meanwhile, the welding current
parameter can be adjusted continuously and steplessly to meet with the requirements of welding
craft.

Single-phase, AC DC AC Trans AC DC AC or DC Hall AC or DC

Rectif Invert Rectif Invert
forme devic
220V，50Hz ier er ier er
r e

Control signal

Current feedback
control

• 2.4. VOLT-AMPERE CHARACTERISTIC

TIG200E AC/DC welding machine has an excellent volt-ampere characteristic, whose graph is
shown as the following figure. The relation between the conventional rated loading voltage U2
and the conventional welding current I2 is as follows:
When I2≤600A，U2=10+0.04I2(V); When I2¬＞600A,U2=34(V).

U2（V）
Volt-ampere characteristic
The relation between the
67 Working conventional loading
point voltage and welding current

34

10

0 600 I2（A）

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 3. Installation & ADJUSTMENT
• 3.1. Parameters
Models
TIG 200E AC/DC TIG 200E AC/DC PULSE
Parameters
Input power (V) 1~220/230/240±10% 1~220/230/240±10%
Fre.（HZ） 50/60HZ 50/60HZ
30.5（AC TIG 39.1（AC MMA 39.1（AC MMA
Rated input current ） ） 30.5（AC TIG） ）
（A） 28.3（DC TIG 40.7（DC MMA 28.3（DC TIG） 40.7（DC MMA
） ） ）
8.6（AC MMA
Rated input power 6.1（AC TIG） 8.6（AC MMA） 6.1（AC TIG） ）
（KW） 6.4（DC TIG） 8.9（DC MMA） 6.4（DC TIG） 8.9（DC MMA
）
AC TIG MMA ＆DC TIG AC TIG MMA ＆DC TIG
Duty cycle（40℃， 35% 200A 40% 170A 35% 200A 40% 170A
10 minutes） 60% 155A 60% 140A 60% 155A 60% 140A
100% 120A 100% 110A 100% 120A 100% 110A
No load voltage (V) 52 52
Adjustment range 10～170
10～200（AC 10～170 10～200（AC
of welding current ( MMA ＆DC
TIG） ( MMA ＆DC TIG) TIG）
（A） TIG)
Down slope（S） 0～10 0～10
Post flow （S） 0～10 0～10
Pulse frequency（
/ 0.5~200
HZ）
AC frequency（HZ
60 60
）
Pulse width range
/ 5~95
（%）
Clearance effect（
15～50 15～50
%）
Efficiency（%） ≥85 ≥85
Power factor 0.6 0.6
Cooling AF AF
Protection class IP23 IP23
Insulation class H H
Dimensions of
Machine (L×W×H) 410×146×278 410×146×278
(mm)
Weight(Kg) 7.0 7.0

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• 3.2. Duty cycle & Over heat
The letter “X” stands for duty cycle, which is defined as the proportion of the time that a machine
can work continuously within a certain time (10 minutes). The rated duty cycle means the
proportion of the time that a machine can work continuously within 10 minutes when it outputs
the rated welding current.
The relation between the duty cycle “X” and the
output welding current “I” is shown as the right
figure.
If the welder is over-heat, the IGBT over-heat
protection unit inside it will output an instruction to
cut output welding current, and brighten the over-
heat pilot lamp on the front panel. At this time, the
machine should be relaxed for 15 minutes to cool
the fan. When operating the machine again, the
welding output current or the duty cycle should be
reduced.

• 3.3. Movement and placement

Please take care for the welder when moving it, and do not make it sloped.
It also can be moved by the handle on the top of the welder. Place the welder well when moving
it to the right position. When the machine gets to the destination, it needs to be fixed up to avoid
gliding.
When using forklift, its arm length must be long enough to reach the outside so as to ensure
lifting safely.
The movement may result in the potential danger or substantive hazard, so please make sure
that the machine is on the safe position before using it.

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• 3.4. Power supply input connection
TIG 200E AC/DC welding machines’ power supply connects to 220V.
When the power supply voltage is over the safe work voltage, there are over voltage and under
voltage protection inside the welder, the alarm light will on, at the same time, the current output
will be cut off.
If the power supply voltage continually goes beyond the safe work voltage range, it will shorten
the welder life-span. The below measures can be used:
Change the power supply input net. Such as, connect the welder with the stable power supply
voltage of distributor;
Induce the machines using power supply in the same time;
Set the voltage stabilization device in the front of power cable input.

• 3.5. Polarity Connection (MMA)

MMA (DC): Choosing the connection of DCEN or DCEP according to the different electrodes.
Please refer to the electrode manual.
MMA (AC): No requirements for polarity connection.

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• 3.6. Assembling the equipment (TIG)
Workpiece is connected to the positive electrode of welding machine, and welding torch is
connected to the negative electrode, which is called DC POSITIVE CONNECTION; otherwise, that is
called DC NEGATIVE CONNECTION. Generally, it is usually operated in DC POSITIVE CONNECTION
in TIG welding mode.
The control cable of torch switch consists of 2 wires, pedal control of 3 wires and the aero socket
has 12 leads.
Consumable parts for TIG torch, such as tungsten electrode、tip、gas nozzle、electrode shield
(short/long), please enquire us by mail or phone according to the accessory codes.
When TIG 200E AC/DC welding machines are operated in HF ignition method, the ignition spark
can cause interferences in equipment near the welding machine. Be sure to take specially safety
precautions or shielding measures.

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 4. OPERATION
• 4.1. Layout for the panel

1. Positive output: The welder’s positive polarity output.

2. Negative output: The welder’s negative polarity output.
3. Aero socket: Is connected to torch switch control wire.（It has 12 leads and lead 8 - lead 9
are connected to torch switch control wire）.
4. Shield gas connector: Is connected to the gas input pipe of torch.
5. Power source switch: Switch to “ON”, the welder is turned on, while switch to “OFF”, the
welder is turned off.
6. Power source input: To connect power source.
7. Shield gas input joint: To connect one head of the gas hose while the other head of which is
connected to argon gas cylinder.

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• 4.2. Control panel

TIG 200E AC/DC

16
 TIG 200E AC/DC PULSE

Available parameters where 2T and 4T mode have been selected:

Tpr Gas pre-flow time
Unit S
Setting range 0.0—2.0

Is Starting current (only with 4T)

Unit A
Setting range 10—170 (DC); 10—200(AC)

Tup Upslope time

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Unit S
Setting range 0.0—10

Ip Welding current
Unit A
10—170 (TIG-DC); 10—200 (TIG-AC);

Ib Base current
Unit A
10—170 (TIG-DC); 10—200 (TIG-AC);

Dcy Ratio of pulse duration to base current duration

Unit %
Setting range 5—95

Fp Pulse frequency
Unit Hz
Setting range 0.5—200

Tdown Downslope time

Unit S
Setting range 0—10

Ic Crater arc current (only with 4T)

Unit A
Setting range 10-170 (DC); 10-200 (AC)

Tpo Gas post-flow time

Unit S
Setting range 0—10

Balance (only with TIG-AC)

Balance adjustment is mainly used to set the adjustment of eliminating metal-oxide (such as
Aluminium, Magnesium and its alloy) while AC output.
Unit
Setting range -5—+5

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• 4.2.1. Pedal switch control
 When plug the fourteen-lead aero-socket of pedal switch in it. Welder will identify the pedal
switch, the welding current knob on the front panel will can’t use，and only 2T can be
selected.
 When use the adjustment knob of max-welding current beside the pedal, can set the max-
current you want.
 The eighth and ninth of the fourteen-lead aero-socket is gun switch; The first and second of
the twelve-lead aero-socket is short circuit; The third、fourth and fifth of the twelve-lead
aero-socket is pedal adjustable resistance.

Adjustment knob of welding

current
Connected to the 12-
lead aero socket on the
front panel
Adjustment knob of max welding current

• 4.2.2. Gun switch control current

Adjust current button, when

Gun switch it’s pushed up, the current
increase, when it’s pushed
down, the current decrease.

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• 4.3. Argon Arc Welding Operation
• 4.3.1. TIG welding (4T operation)
The start current and crater current can be pre-set. This function can compensate the possible
crater that appears at the beginning and end of the welding. Thus, 4T is suitable for the welding
of medium thickness plates.

Introduction:
0: Press and hold the gun switch, Electromagnetic gas valve is turned on. The shielding gas stars to
flow;
0～t1: Pre-gas time (0~2S);
t1～t2: Arc is ignited at t1 and then output the setting value of start current;
t2: Loosen the gun switch, the output current slopes up from the start current;
t2～t3: The output current rises to the setting value (Iw or Ib), the upslope time can be adjusted;
t3～t4: Welding process. During this period, the gun switch is loosen;
Note: Select the pulsed output, the base current and welding current will be outputted
alternately; otherwise, output the setting value of welding current;
t4: Press the torch switch again, the welding current will drop in accordance with the selected
down-slope time.
t4～t5: The output current slopes down to the crater current. The downslope time can be
adjusted;
t5～t6: The crater current time;
t6: Loosen the gun switch, stop arc and keep on argon flowing;
t6～t7: Post-gas time can be set by the post-gas time adjustment knob on the front panel (0～
10S);
t7: Electromagnetic valve is closed and stop argon flowing. Welding is finished.

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• 4.3.2. TIG welding (2T operation)
This function without the adjustment of start current and crater current is suitable for the Re-
tack welding、transient welding、thin plate welding and so on.

I（A）

Welding current Is
Loosen the
welding gun
switch
The setting base
current Ib
Press and hold the welding Arc is Arc is
gun switch ignited turned off

0 t1 t2 t3 t4 t5 t（s）

Introduction：
0: Press the gun switch and hold it. Electromagnetic gas valve is turned on. The shielding gas stars
to flow.
0～t1: Pre-gas time (0~2s)
t1～t2: Arc is ignited and the output current rises to the setting welding current (Iw or Ib) from
the min welding current.
t2～t3: During the whole welding process, the gun switch is pressed and held without releasing.
Note: Select the pulsed output, the base current and welding current will be outputted
alternately; otherwise, output the setting value of welding current;
t3: Release the gun switch, the welding current will drop in accordance with the selected down-
slope time.
t3～t4: The current drops to the minimum welding current from the setting current (Iw or Ib), and
then arc is turned off.
t4～t5: Post-gas time, after the arc is turned off. You can adjust it (0~10s) through turnning the
knob on the front panel.
t5: electromagnetic gas valve turned off, the shield gas stops to flow, and welding is finished.
Short circuit protect function:
1. TIG /DC/LIFT: If the tungesten electrode touches the workpiece when welding, the current
will drop to 20A, which can reduce the tungsten spoilage farthestly，prolong the using
life of the tungsten electrode，and prevent tungsten clipping.
2. TIG /DC/HF: If the tungesten electrode touches the workpiece when welding, the current
will drop to 0 within 1s, which can reduce the tungsten spoilage farthestly，prolong the
using life of the tungsten electrode，and prevent tungsten clipping.
3. MMA operation: if the electrode touches workpiece over two seconds, the welding
current will drop to the 0 automatically to protect the electrode.
Prevent arc-break function: TIG operation, Avoid arc-break with special means, even if
arc-break occurs the HF will keep the arc stable

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 4. TIG：If the TIG torch is pressed quickly, the welding current will drop a half, then if the
TIG torch is pressed quickly again, the welding current will get back.

Notices:
Check the condition of welding and connection units firstly, otherwise there will be malfunction
such as ignition spark、gas leakage、out of control and so on.
Check that whether there is enough Argon gas in the shield gas cylinder, you can test the
electromagnetic gas valve through the switch on the front panel.
Do not let the torch aim at your hand or else of your body. When you press the torch switch, the
arc is ignited with a high-frequency, high-voltage spark, and the ignition spark can cause
interferences in equipment.
The flow rate is set according to the welding power used in the job. Turn the regulation screw to
adjust the gas flow which is shown on the gas hose pressure meter or the gas bottle pressure
meter.
The spark ignition works better if you keep the 3mm distance from the workpiece to the tungsten
electrode during the ignition.
Note: When select AC output, the current and the wave form are as same as the above, but
output polarity changes alternately.

• 4.4. Welding Parameters

• 4.4.1. Joint forms in TIG/MMA

a butt joint b lap joint c coner joint d T joint

• 4.4.2. The explanation of welding quality

The relation of welding area color & protect effect of stainless steel
Welding area argent ,
blue red-grey grey black
color golden
Protect effect best better good bad worst

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 The relation of welding area color & protect effect of Ti-alloy
white powder
Welding area orange- blue-
bright argent caesious of titanium
color yellow purple
oxid
Protect effect best better good bad worst

• 4.4.3. TIG Parameters Matching

The corresponding relationship between gas nozzle diameter and
electrode diameter
Gas nozzle diameter/mm Electrode diameter/mm

6.4 0.5

8 1.0

9.5 1.6 or 2.4

11.1 3.2
Notice: the above parameters originate from “Welding Dictionary” P142,
Volume 1 of Edition 2.

Gas nozzle and the shield gas flow rate

DC positive connection AC
Welding current
range/A Gas nozzle Gas flow Gas nozzle Gas flow
diameter/mm rate/L·min-1 diameter/mm rate/L·min-1
10～100 4～9.5 4～5 8～9.5 6～8
101～150 4～9.5 4～7 9.5～11 7～10
151～200 6～13 6～8 11～13 7～10
201～300 8～13 8～9 13～16 8～15
Notice: the above parameters originate from “Welding Dictionary” P149, Volume 1 of Edition 2.

sharpened of the
tungsten electrode
electrode angle of cone（°） background current/A
diameter /mm
diameter/mm
1.0 0.125 12 2～15
1.0 0.25 20 5～30
1.6 0.5 25 8～50
1.6 0.8 30 10～70
2.4 0.8 35 12～90
2.4 1.1 45 15～150

23
3.2 1.1 60 20～200

TIG of stainless steel (single run welding)

tungsten welding
Workpiece Argon gas welding Welding
electrode wire
thickness Joint form flow rate/ current speed/
diameter/m diameter/m
/mm L·min-1 (DCEP) cm·min-1
m m
0.8 Butt joint 1.0 1.6 5 20～50 66
1.0 Butt joint 1.6 1.6 5 50～80 56
1.5 Butt joint 1.6 1.6 7 65～105 30
Corner
1.5 1.6 1.6 7 75～125 25
joint
2.4 Butt joint 1.6 2.4 7 85～125 30
Corner
2.4 1.6 2.4 7 95～135 25
joint
3.2 Butt joint 1.6 2.4 7 100～135 30
Corner
3.2 1.6 2.4 7 115～145 25
joint
4.8 Butt joint 2.4 3.2 8 150～225 25
Corner
4.8 3.2 3.2 9 175～250 20
joint
Notice: the above parameters originate from “Welding Dictionary” P150, Volume 1 of Edition 2.

Parameters of piping back sealing welding for mild Steel (DCEP)

Piping Tungsten Welding Argon Welding
Gas nozzle Welding Arc
diamet electrode wire flow rate
diameter/m current/ voltage/
erΦ/m diameter/m diameter/m rate / cm·min-
m A V
m m m / L·min-1 1

38 2.0 8 2 75～90 11～13 6～8 4～5

42 2.0 8 2 75～95 11～13 6～8 4～5
60 2.0 8 2 75～100 11～13 7～9 4～5
76 2.5 8～10 2.5 80～105 14～16 8～10 4～5
108 2.5 8～10 2.5 90～110 14～16 9～11 5～6
133 2.5 8～10 2.5 90～115 14～16 10～12 5～6
159 2.5 8～10 2.5 95～120 14～16 11～13 5～6
100～
219 2.5 8～10 2.5 14～16 12～14 5～6
120
110～
273 2.5 8～10 2.5 14～16 12～14 5～6
125
120～
325 2.5 8～10 2.5 14～16 12～14 5～6
140
Notice: the above parameters originate from “Welding Dictionary” P167, Volume 1 of Edition 2.

24
 Parameters of AC TIG (MMA) for Aluminum and its alloy
Tungste
Argon
Weldin n Pre- Gas
Sheet Weldin flow
g wire electrod heat nozzle
thicknes g rate Remark
diamet e Temper diamet
s current
er diamete -ature er
/mm /A / L·min-
/mm r /℃ 1 /mm
/mm
Flange
1 1.6 2 － 45～60 7～9 8
welding
Flange or
1.6～
1.5 2 － 50～80 7～9 8 butt welding
2.0
by one side
90～
2 2～2.5 2～3 － 8～12 8～12 Butt welding
120
150～
3 2～3 3 － 8～12 8～12
180
180～
4 3 4 － 10～15 8～12
200
180～
5 3～4 4 － 10～15 10～12
240
240～
6 4 5 － 16～20 14～16
280
260～
8 4～5 5 100 16～20 14～16
320
100～ 280～ V-groove
10 4～5 5 16～20 14～16
150 340 butt welding
150～ 300～
12 4～5 5～6 18～22 16～20
200 360
180～ 340～
14 5～6 5～6 20～24 16～20
200 380
200～ 340～
16 5～6 6 20～24 16～20
220 380
200～ 360～
18 5～6 6 25～30 16～20
240 400
200～ 360～
20 5～6 6 25～30 20～22
260 400
200～ 300～
16～20 5～6 6 25～30 16～20
260 380 X-groove
200～ 360～ butt welding
22～25 5～6 6～7 30～35 20～22
260 400
Notice: the above parameters originate from《Welding Dictionary》P538, Volume 2 of Edition 2.

25
• 4.5. Operation Environment
 Height above sea level is below 1000m.
 Operation temperature range:-100C～+400C.
 Relative humidity is below 90 % (200C).
 Preferably site the machine some angles above the floor level, the maximum angle does not
exceed 150.
 Protect the machine against heavy rain or in hot circumstance against direct sunshine.
 The content of dust, acid, corrosive gas in the surrounding air or substance can not exceed
normal standard.
 Take care that there is sufficient ventilation during welding. There is at least 30cm free
distance between the machine and wall.

• 4.6. Operation Notices

 Read §1 carefully before attempting to use this equipment.
 Connect the ground wire with the machine directly, and refer to §3.5.
 In case closing the power switch, no-load voltage may be exported. Do not touch the output
electrode with any part of your body.
 Before operation, no concerned people should be left. Do not watch the arc in unprotected
eyes.
 Ensure good ventilation of the machine to improve duty ratio.
 Turn off the engine when the operation finished to economize energy source.
 When power switch shuts off protectively because of failure. Don’t restart it until problem is
resolved. Otherwise, the range of problem will be extended.

26
 5. Maintenance & Troubleshooting
• 5.1. Maintenance
In order to guarantee that arc welding machine works high-efficiently and in safety, it must be
maintained regularly. Let customers understand the maintenance methods and means of arc
welding machine more, enable customers to carry on simple examination and safeguarding by
oneself, try one's best to reduce the fault rate and repair times of arc welding machine, so as to
lengthen service life of arc welding machine .Maintenance items in detail are in the following
table.

● Warning: For safety while maintaining the machine, please shut off the supply power and
wait for 5 minutes, until capacity voltage already drop to safe voltage 36V!
date Maintenance item
Observe that whether panel knob and switch in the front and at the back of arc
welding machine are flexible and put correctly in place. If the knob has not been put
correctly in place, please correct; If you can't correct or fix the knob , please replace
immediately;
If the switch is not flexible or it can't be put correctly in place, please replace
immediately; Please get in touch with maintenance service department if there are no
accessories.
After turn-on power, watch/listen to that whether the arc welding machine has
shaking, whistle calling or peculiar smell. If there is one of the above problems, find
out the reason to get rid of; if you can't find out the reason, Please contact local this
area agent or the branch company.
Observe that whether the display value of LED is intact. If the display number is not
Daily
intact, please replace the damaged LED. If it still doesn’t work, please maintain or
examinatio
replace the display PCB.
n
Observe that whether the min/max value on LED accords with the set value. If there is
any difference and it has affected the normal welding craft, please adjust it.
Check up that Whether fan is damaged and is normal to rotate or control. If the fan is
damaged, please change immediately. If the fan does not rotate after the arc welding
machine is overheated, observe that whether there is something blocked in the blade,
if it is blocked, please get rid of; If the fan does not rotate after getting rid of the
above problems, you can poke the blade by the rotation direction of fan. If the fan
rotates normally, the start capacity should be replaced; If not, change the fan.
Observe that whether the fast connector is loose or overheated. If the arc welding
machine has the above problems, it should be fastened or changed.
Observe that Whether the current output cable is damaged. If it is damaged, it should
be wrapped up, insulated or changed.

27
 Using the dry compressed air to clear the inside of arc welding machine. Especially for
Monthly clearing up the dusts on radiator, main voltage transformer, inductance, IGBT module,
examinatio the fast recover diode and PCB, etc.
n Check up the bolt in arc welding machine, if it is loose, please screw down it. If it is
skid, please replace. If it is rusty, please erase rust on bolt to ensure it works well.

Quarter-
Whether the actual current accords with the displaying value. If they does not accord,
yearly
they should be regulated. The actual current value can be measured by the adjusted
examinatio
plier-type ampere meter.
n
Yearly Measure the insulating impedance among the main circuit, PCB and case, if it below
examinatio 1MΩ, insulation is thought to be damaged and need to change, and need to change or
n strengthen insulation.

• 5.2. Troubleshooting
Before arc welding machines are dispatched from the factory, they have already been debugged
accurately. So forbid anyone who is not authorized by us to do any change to the equipment!
Maintenance course must be operated carefully. If any wire becomes flexible or is misplaced, it
maybe potential danger to user!
Only professional maintenance personal who is authorized by us could overhaul the machine!
Guarantee to shut off the arc welding machine’s power before turn on the outline of the
equipment!
If there is any problem and has no the authorized professional maintenance personal, please
contact local agent or the branch company!
If there are some simple troubles of TIG200E AC/DC -series welding machine, you can consult the
following overhauling chart:

S/N Troubles Reasons Solution

The power light damaged or

Turn on the power source, Check and repair Pr7
connection is not good
and fan works, but the
1
power pilot lamp is not Repair or change the
on. The transformer of power is broken
transformer
Control PCB failures Repair or change the control Pr4

There is something in the fan Clear out

Turn on the power source,
2 and the power lamp is on, The start capacitor of fan damaged Change capacitor
but fan doesn’t work
The fan motor damaged Change fan
Check whether there is power
3 No power supply input
supply

28
S/N Troubles Reasons Solution
Turn on the power source,
The fuse inside the machine
the power lamp is not on, Change it (3A)
damaged
and fan doesn’t work
The number on the display
4 The LED in the display is broken Change the LED
is not intact.
The max value is not accordant Adjust potentiometer Imin on
The max and min value
(refer to §3.1) the power board.
5 displayed doesn’t accord
The min value is not accordant Adjust potentiometer Imaxin the
with the set value.
(refer to §3.1) current meter.
No no-load voltage output Check the main circuit and the
6 The machine is damaged
(MMA) Pr4.
The welding cable is not connected Connect the welding cable to the
with the two output of the welder. welder’s output.
The welding cable damaged. Repair or change it.
There is
The earth cable connected unstably. Check the earth cable.
spark on
Use an appropriate welding
the HF The welding cable is too long.
cable.
igniting
There is oil or dust on the
Arc can not board. workpiece.
Check and remove it.
7 be ignited The distance between tungsten Reduce the distance (about
(TIG) electrode and workpiece is too long. 3mm).
The HF igniting board does not
There is not Repair or change Pr8
work.
spark on
the HF The distance between the Adjust this distance (about
igniting discharger is too short. 0.7mm).
board. The malfunction of the welding gun Check the welding gun switch,
switch. control cable and aero socket.
Gas cylinder is close or gas pressure
Open or change the gas cylinder
is low
8 No gas flow (TIG)
Something in the valve Remove it
Electromagnetic valve is damaged Change it
The gas-test on the front panel is
The gas-test on the front panel is on
off
Gas always flows Something in the valve Remove it
9 Electromagnetic valve is damaged Change it
The adjustment knob of pre-gas
Repair or change it
time on the front panel is damaged
The welding current potentiometer
The welding current can Repair or change the
10 on the front panel connection is not
not be adjusted potentiometer
good or damaged
The power PCB is in trouble. Repair or change it.
No AC output while
11 The AC drive PCB damaged. Change it.
selecting “AC”
The AC IGBT module damaged. Change it.
The welding current The min value displayed isn’t
Adjust potentiometer Imin on
12 displayed isn’t accordant accordant with the actual value.
the power board.
with the actual value. (Please refer to §3.1)

29
S/N Troubles Reasons Solution
The max value displayed isn’t
Adjust potentiometer Imax on
accordant with the actual value.
the power board.
(Please refer to §3.1)
The welding current is adjusted too
Increase the welding current
The penetration of molten low
13
pool is not enough. The arc is too long in the welding
Use 2T operation
process
Two much Reduce the welding current
Over heat welding current output
protection Working time Reduce the duty cycle (work
too long intermittently)
Over-voltage Power supply
Using the stable power supply
protection fluctuates
Power supply
The alarm lamp on the Using the stable power supply
14 fluctuates
front panel is on
Low-voltage Too many
protection machines using Reduce the machines using
power supply in power supply in the same time
the same time
Unusual current
Over-current Check and repair the main circuit
in the main
protection and drive Pr6
circuit

30
• 5.3. Electrical principle drawing

31
200TIGP AC/DC
STICK • TIG

32